Modular Overhead Storage

ABSTRACT

A storage system comprises a rack of multiple platforms connectable to one another in a first direction, where each of the platforms has segments that connect to one another along a direction other than the first direction, via a user-operable coupling. The platforms are preferably rectangular, and are connected at their long ends. The segments of each platform are also preferably rectangular, but they are connected along their long sides. In such embodiments, the connection between platforms is perpendicular to the length of the rack, while the connection between segments is parallel to the length of the rack. The segments of individual platforms are preferably coupled together with snap fit connections, and supported from their undersides by transverse supports, and the transverse supports are supported from their undersides by longitudinal supports via recesses on the segments. The transverse supports are preferably perpendicular to the longitudinal supports.

This application is a continuation of U.S patent application Ser. No.14/166,123 filed on Jan. 28, 2014, which is a divisional of U.S. patentapplication Ser. No. 12/974,801 filed on Dec. 21, 2010, which is acontinuation-in-part and claims priority to U.S. patent application Ser.No. 11/479,480 filed Jun. 30, 2006, which claims the benefit of U.S.Provisional Application No. 60/726,746 filed Oct. 14, 2005 and U.S.Provisional Application No. 60/697,468 filed Jul. 7, 2005. These and allother extrinsic materials discussed herein are incorporated by referencein their entirety. Where a definition or use of a term in anincorporated reference is inconsistent or contrary to the definition ofthat term provided herein, the definition of that term provided hereinapplies and the definition of that term in the reference does not apply.

FIELD OF THE INVENTION

The field of the invention is overhead suspension storage racks.

BACKGROUND

Many different types of overhead storage racks are known. Overheadstorage racks are typically hung from the ceiling to provide storagespace where space is at a premium, such as a garage.

One problem with known storage racks, whether overhead or floorsupported, is that the width is limited to that of a single plank,platform, or other member. See, e.g., U.S. Pat. No. 1,260,123 to Areson,U.S. Pat. No. 3,832,957 to Mendenhall, U.S. Pat. No. 6,725,608 to Kraus,and U.S. Pat. No. 7,152,535 to Mikich et al. This causes wholesalers andretailers to stock several different widths to accommodate differentuser demands, which in turn consumes valuable floor and storage space,and requires higher inventory costs.

Thus, there is still a need for modular overhead storage racks that arerelatively compact, allowing desirable retail packing, and assembleseasily.

SUMMARY OF THE INVENTION

The present invention provides apparatus, systems and methods in which astorage system comprises a rack of multiple platforms connectable to oneanother in a first direction, where each of the platforms has segmentsthat connect to one another along a direction other than the firstdirection, via a user-operable coupling.

In a preferred embodiment, the platforms are rectangular, and areconnected at their long ends. The segments of each platform are alsorectangular, but they are connected along their long sides. In suchembodiments, the connection between platforms is perpendicular to thelength of the rack, while the connection between segments is parallel tothe length of the rack. The segments of individual platforms arepreferably coupled together with snap fit connections, and supportedfrom their undersides by transverse supports, and the transversesupports are supported from their undersides by longitudinal supports.The transverse supports are preferably perpendicular to the longitudinalsupports.

Each of the platform has end segments that have a series of recesses onits underside. The recesses are to couple a respective segment of aportion of the longitudinal support beams or an adjuster of thelongitudinal support beams so said portion of the support beams isembedded into the recesses.

Adjacent platforms can be coupled in any suitable manner, including atthe ends of the longitudinal supports. Adjacent platforms may, but neednot touch one another.

Each of the platforms in the rack can advantageously be supported fromabove by one, two, or more pairs of legs. Legs can alternatively oradditionally be disposed between the platforms. Preferred legs aretelescoping, allowing easy adjustment of their lengths. It is furthercontemplated that the telescoping mechanism can have a finger operabledetent that cooperates with a catch to fix the length until the user caninsert a secure pin.

In another aspect, a polymeric ring can be advantageously positioned atan end of one of the telescoping components of a leg to reduce noise andvibration. Similarly, polymeric rings can be placed at the ends of thelongitudinal supports.

Various objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of preferred embodiments of the invention, along with theaccompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of a storage rack having three platforms.

FIG. 2 is an exploded perspective view a platform of FIG. 1.

FIG. 3 is non-exploded view of the platform of FIG. 2.

FIG. 4 is an exploded perspective view of a pair of longitudinalsupports, and corresponding pairs of legs.

FIG. 5 is a non-exploded perspective view of the pair of longitudinalsupports, and corresponding pairs of legs of FIG. 4.

FIG. 6 is an exploded perspective view of a telescoping member of a legshowing a detent and a polymeric ring.

FIG. 7 is a exploded perspective view of a leg

FIG. 8 is a non-exploded perspective view of the leg of FIG. 7.

FIG. 9 is an exploded perspective view an embodiment of the platform ofFIG. 1.

FIG. 10 is a non-exploded view of the platform of FIG. 9.

FIG. 11 is a perspective view of an alternative embodiment usingaluminum slats instead of plastic platforms.

DETAILED DESCRIPTION

In FIG. 1, a storage rack 1 generally includes platforms 10A, 10B, and10C, and legs 20. Each of the platforms 10A, 10B, and 10C comprisesthree segments 12A1-12A3 for platform 10A, 12B1-12B3 for platform 10B,12C1-12C3 for platform 10C. There is a pair of transverse supports30A-30C underneath each of the platforms, and two longitudinallyoriented supports 40A-40C beneath each of the pairs of transversesupports 30A-30C, respectively. The platforms 10A, 10B, and 10C arecoupled together at the ends of the longitudinally oriented supports40A-40C via a series of recesses 14A1-14A2 for segments 12A1 and 12A3,recesses 14B1-14B2 for segments 12B1 and 12B3, 14C1-14C2 for segments12C1 and 12C3, respectively, and held from above using legs 20.

It should be apparent from FIG. 1 that the various platforms areconnected to one another in a first direction 50, whereas each of theplatforms has segments that connect to one another along a seconddirection 60, which is not only different from the first direction 50but perpendicular to the first direction 50.

Those skilled in the art will immediately appreciate that rack 1 can beextended or reduced in length by adding or removing platforms. Rack 1can also be extended or reduced in width by adding or reducing thenumber of segments in the different platforms. It should even bepossible to have a rack with platforms having different lengths anddifferent widths. For adjacent segments having different widths, thelongitudinal supports may be coupled using a zigzag connector. It shouldalso be appreciated that the legs on the racks disclosed herein couldstand on the floor, or that a side-connecting mechanism could be used tohang a rack on a wall.

Platforms can comprise any suitable material or materials, including,for example, metal, polymers, and so forth. In a preferred embodimentthe segments of the platforms are made of lightweight plastic, wiremesh, wood, or any other suitable material. Further, the platforms canhave suitable size and configuration, including especiallyconfigurations that are sized and dimensioned to accommodate standardcardboard banker's boxes.

In FIGS. 2 and 3 platform 10A comprises three segments 12A1-12A3. Thesesegments are shown as being substantially rectangular, but canalternatively have any suitable shape, including for example, square,triangular, or having straight ends and curved or waved sides. Eachsegment can have any suitable width, but preferably none of the segmentsis more than 40% of the broadest width of the platform, and morepreferably none is more than 30% of the broadest width of the platform.From a marketing standpoint it is desirable for the various segments tobe sized and dimensioned for convenient packaging, storage, andtransportation.

Segments 12A1-12A3 are shown as having a lattice structure, which isrelatively lightweight and is suitable for holding boxes, bags, and soforth. Other structures are also contemplated, including for example,structures with a solid top such as can be constructed using blow-moldedplastic with internal baffles. Such structures can be advantageous inthat they would prevent a spilled or leaked liquid from flowing downfrom the platform.

The segments 12A1-12A3 can be coupled in any suitable manner to eachother, including simple juxtaposition, snap-fits, tongue and groove, andso forth. In FIGS. 1-3 the various segments are coupled using a snap-fitmechanism 16, in which the sides of one of an adjacent segments has amating and interlocking male extension connector 17A, and the other oneof an adjacent segment has a corresponding receiving area 18A. Anotherembodiment of coupler is shown in FIGS. 9-10. Regardless of themechanism(s) used, it is preferred that the inter-segment couplings areuser operable, meaning that a typical end-user can connect anddisconnect adjacent segments with a minimum of effort, and mostpreferably without any tools.

Also shown in FIGS. 1-3, platforms 10A, 10B, and 10C are connected tothe supports 40A, 40B, and 40C via a series of recesses 14A1-14A2,14B1-14B2, and 14C1-14C2. Recesses 14A1-14A2 are preferably locatedorthogonally from the snap-fit mechanisms 16. Preferably, there are tworecesses per each of the end segments, but depending on theconfiguration of the segments, there can be more or less recesses on agiven segment to accommodate the supports. As used herein, recesses14A1-14B1 can be a groove, a slot or any space that has a width and adepth to accommodate the width and the depth of supports 40A, 40B, or40C or the width and the depth of adjuster 42 that is coupled to thesupports, respectively for a secure and tight fit. The adjuster orsupports can either be coupled to the recesses via a snap-fit mechanism.Regardless of the mechanism(s) used and whether segments 12A1 and 12Care coupled to supports 40B, or 40C or the adjuster 42, it is preferredthat the inter-segment couplings are user operable, meaning that atypical end-user can connect and disconnect each platform and segmentsfrom the supports with a minimum of effort, and most preferably withoutany tools.

As used herein, and unless the context dictates otherwise, the term“coupled to” is intended to include both direct coupling (in which twoelements that are coupled to each other contact each other) and indirectcoupling (in which at least one additional element is located betweenthe two elements). Therefore, the terms “coupled to” and “coupled with”are used synonymously.

To provide added stability, the segments 12A1-12A3 are preferably moldedor otherwise constructed to include collinear channels on theirundersides, which are sized and dimensioned to receive correspondingones of the transverse supports 30A-30C. Segments advantageously havefingers 15 that cooperate to help hold the transverse supports to thecorresponding segments.

From a marketing standpoint, one or more of the segments can have a logo19. Also, while these Figures illustrate a platform having threesegments, it should be appreciated that other quantities of segments canbe combined to create a platform. Preferably, a platform is made bycombining six segments.

Unless the context dictates the contrary, all ranges set forth hereinshould be interpreted as being inclusive of their endpoints, andopen-ended ranges should be interpreted to include commerciallypractical values. Similarly, all lists of values should be considered asinclusive of intermediate values unless the context indicates thecontrary.

FIGS. 4-8 show a pair of longitudinally oriented supports 40A and fourlegs 20. Adjacent supports can be coupled in any suitable manner, butare here shown as being coupled using an adjuster 42. Preferablyadjuster 42 can be an intervening pin or any length of a segment thatcouples to supports 40A so as to make the supports longer and moresecure. Alternatively, the ends of adjacent supports could be coupledusing a sleeve (not shown). To reduce noise and vibration one can alsoinclude a polymeric ring 44 about an end of one or more of the supports.

Each of legs 30 generally includes two telescoping members 32A, 32B. Toreduce noise and vibration one can include another polymeric ring 36about an end of one or more of the members 32A, 32B. Distal ends of legs30 preferably have corner mount structures 34 to facilitate mounting ofthe legs to a ceiling, either by horizontally-driven orvertically-driven fastening means, including nails and screws. The legs30 can advantageously include a finger operable detent 38 thatcooperates with a catch 39 to fix a length of the leg 30. A security pin37 can be used to lock the telescoping members 32A, 32B at a fixedlength.

Legs 30 can be coupled to the platforms in any suitable manner. Toprovide significant strength and stability, legs 30 preferably include achannel through which extends the adjuster 42, or one or both ofadjacent longitudinally oriented supports (not shown). A cap 46 can beused at the terminal end of a longitudinally oriented support or theadjuster 42.

FIGS. 9-10 show an embodiment of platform 115 having segments112B1-112B3 that are coupled by snap-fit connectors, the snap-fitconnector comprises male member 117B, and female member 118B. The malemembers 117B has user operable fingers 117C that can be biased by anuser to disconnect the segments. In operation, a user would bias thefingers 117C towards each other, thereby enabling the exiting of malemember 117B from female member 18B. Recesses 114A-114B located on theends of segments 112B1 and 112B3 can connect the platform 115 tosupports (not shown).

FIG. 9 shows another embodiment of the transverse support. Here, asoppose to a solid flat metal strip as shown in FIG. 2, transversesupport 130B is made of sheet metal and has a cross-sectionalconfiguration that enhances structural integrity. FIG. 9 shows across-section configuration similar to a “C.” Other suitable shapes andconfiguration are also possible and is readily appreciated by one ofordinary skill in the art to provide structural integrity. The use ofsheet metal is also advantageous in that sheet metal transverse supportis lighter and easier to manufacture than a solid piece of metal strip.

In FIG. 10, transverse support 130B is secured in place by stop tab 116.Stop tab 116 is disposed on segments that receives the two ends of thetransverse support. Here, the two ends of transverse support 130B isreceived by segments 112B1 and 112B3. Stop tab 116 is a protrusionpreferably formed from the segments to keep the transverse support. Thefunction of stop tab 116 is similar to that of finger 15 in FIG. 3.

In FIG. 11, an alternative design of a storage rack 101, generallyincludes platforms 110A, 110B, and 110C, and legs 120. Each of theplatforms 110A, 110B, and 110C comprises five slats 112A1-112A5 forplatform 110A, 112B1-112B5 for platform 110B, 112C1-112C5 for platform110C. There is a pair of longitudinally oriented supports 140A-140Brunning beneath all of the slats. The longitudinally oriented supports140A-140B are held from above using legs 120.

The slats can comprise any suitable material, including especiallyaluminum or other metal, alloy, or composite. Although five appearsexperimentally to be an optimum number of slats, it is contemplated thatone could have platforms with a greater of lesser number of slats thanfive, and indeed different platforms could have different numbers ofslats. Where the slats contain metal, it is considered to beadvantageous from weight and cost bases for the slats to be hollow, orto have “I”, “C”, “E”, “H” or other cross-sections.

Thus, specific embodiments and applications of modular overhead storagehave been disclosed. It should be apparent, however, to those skilled inthe art that many more modifications besides those already described arepossible without departing from the inventive concepts herein. Theinventive subject matter, therefore, is not to be restricted except inthe spirit of the appended claims. Moreover, in interpreting both thespecification and the claims, all terms should be interpreted in thebroadest possible manner consistent with the context. In particular, theterms “comprises” and “comprising” should be interpreted as referring toelements, components, or steps in a non-exclusive manner, indicatingthat the referenced elements, components, or steps may be present, orutilized, or combined with other elements, components, or steps that arenot expressly referenced. Where the specification claims refers to atleast one of something selected from the group consisting of A, B, C . .. and N, the text should be interpreted as requiring only one elementfrom the group, not A plus N, or B plus N, etc.

What is claimed is:
 1. An overhead storage assembly, comprising: a firstlongitudinal support beam and a second longitudinal support beam; aplurality of slats that couple to the first and second longitudinalsupport beams and that extend from the first longitudinal support beamto the second longitudinal support beam to provide a platform; aplurality of extendable legs that couple to the first and secondlongitudinal support beams for suspending the platform; and wherein eachleg comprises; an inner member having a hole sized and dimensioned toreceive a locking mechanism; an outer member having a first catch and asecond catch that are sized and dimensioned to receive the lockingmechanism; and wherein the first catch and second catch are radiallyoffset from one another with respect to the longitudinal axis of theouter member.
 2. The assembly of claim 1, wherein when the first catchis aligned with the hole, the locking mechanism fixes the inner memberto the outer member in a first position and at a first length.
 3. Theassembly of claim 2, wherein when the second catch is aligned with thehole, the locking mechanism fixes the inner member to the outer memberin a second position and at a second length.
 4. The assembly of claims3, wherein the first length and second length are different.
 5. Theassembly of claim 1, wherein the locking mechanism is a pin or a detent.6. The assembly of claim 1, further comprising a mount structure coupledto the inner member for mounting the leg to a ceiling.
 7. The assemblyof claim 1, wherein the inner member and outer member each have a squarecross-sectional shape, thereby allowing four different rotationalorientations of the inner member and outer member with respect to oneanother.
 8. The assembly of claim 1, wherein the cross-sectional shapeof the inner member is geometrically similar to the cross-sectionalshape of the outer member.
 9. An overhead storage assembly comprising: afirst longitudinal support beam and a second longitudinal support beam;a plurality of slats that extend from the first longitudinal supportbeam to the second longitudinal support beam to provide a platform whencoupled to the first and second longitudinal support beams; a pluralityof extendable legs that couple to the first and second longitudinalsupport beams for suspending the platform; and wherein each legcomprises; a first member having a hole sized and dimensioned to receivea locking mechanism; a second member having a first plurality of catchesand a second plurality of catches that are sized and dimensioned toreceive the locking mechanism; wherein the first plurality of catchesare aligned along a first axis; and wherein the second plurality ofcatches are aligned along a second axis that is parallel to the firstaxis.
 10. The assembly of claim 9, wherein at least a portion of thefirst member fits within at least a portion of the second member. 11.The assembly of claim 9, wherein at least a portion of the second memberfits within at least a portion of the first member.
 12. The assembly ofclaim 9, wherein the plurality of extendable legs further comprise achannel sized and dimensioned to receive and support an end of the firstlongitudinal support beam.
 13. The assembly of claim 9, wherein thefirst and second longitudinal support beams are configured to couple toa third longitudinal support beam and a fourth longitudinal supportbeam, respectively.
 14. An overhead storage assembly having a firstdirection and a second direction, comprising: a plurality of telescopinglegs, wherein each leg comprises a first member that slidably coupleswith a second member, and wherein the first member has a channel that issized and dimensioned to receive at least one of a plurality ofadjusters; wherein each of the plurality of adjusters is sized anddimensioned to couple with one of a plurality of support members;wherein the support members and adjusters align along the firstdirection when coupled together; and a plurality of panels that coupleto adjacent ones of the plurality of support members and align along thesecond direction.
 15. The assembly of claim 14, wherein each of theplurality of adjusters slidably couples with at least one of thechannels.
 16. The assembly of claim 14, wherein each of the plurality ofsupport members slidably couples with at least one of the plurality ofadjusters.
 17. The assembly of claim 14, further comprising a bushingsized and dimensioned to fit in the channel and around the end of theadjuster.
 18. The assembly of claim 14, further comprising a cap sizedand dimensioned to fit inside the adjuster.
 19. The assembly of claim14, wherein each of the plurality of support members is hollow and issized and dimensioned to slidably receive at least one of the pluralityof adjusters.
 20. The assembly of claim 14, wherein each of theplurality of adjusters has a plurality of catches for receiving alocking mechanism, and wherein each of the plurality of support membershas a hole for receiving the locking mechanism.